Annual Condition Checklist Template by Randy Pflanzer (rpflanzer@fssa.state.in.us)
Inspection Details:
Location of Inspection:________________________ Date of Inspection:___________________
Aircraft Owner:______________________________ Total Airframe Hours:_________________
Mechanic:__________________________________ Total Engine Hours:__________________
Certificate Number:___________________________ Total Propeller Hours:_________________
Annual inspection Consumables:
- Oil filter (Champion CH48110) (Engine Lubrication Group)
- Oil (7 qts Phillips 20W50) (Engine Lubrication Group)
- Oil sample kit (Aviation Laboratories) (Engine Lubrication Group)
- Vacuum regulator garter filter (Airborne B3-5-1) (Cabin Mechanical Group)
- Vacuum system pleated filter (Airborne D9-18-1) (Cabin Mechanical Group)
- Hydraulic fluid (MIL-H-5606) (Engine Firewall Group)
- ELT batteries (6 Duracell MN1300) (Cabin Electrical Group)
- ELT remote sensor battery (1 - Duracell DL 1/3 NB) (Cabin Electrical Group)
- K&N air filter recharge kit (K&N 99-5000) (Engine Intake Group)
- Brake lining replacement kit (Landing Gear Group)
- Stainless steel screws (22 AN526C-832R8) (Propeller Group)
- Stainless steel screws (22 AN526C-832R8) (Operational Inspection)
- Tire inner tubes (2 5:00X5-6IT) (Landing Gear Group)
Date/Time Installed Log:
Installed
- Tire inner tubes (replace every 3 years) June 2000
- ELT batteries (replace every 2 years) June 2000
- ELT remote sensor battery (replace every 2 years) June 2000
- Vacuum system pleated filter (replace every 500 hours) 0 hours
Engine - Propeller Group:
- Remove spinner noting alignment marks
- Remove propeller bolts and inspect for galling, cracks, etc.
- Inspect spinner and backplate for cracks or damaged nutplates
- Inspect crankcase nose seal for oil leaks
- Inspect propeller blades for nicks, cracks and/or surface erosion, repair as necessary
- Inspect hub for cracks and/or corrosion
- Re-install propeller mounting bolts, torque, and safety wire noting alignment marks
- Check propeller track
- Re-install spinner using new fasteners
- NOTES:________________________________________________________________
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Engine - Cowling Group:
- Remove cowling joining screws, upper hinge pins, and remove upper cowling
- Remove lower hinge pins, side hinge pins, and remove lower cowling
- Inspect hinges for broken eyelets, excessive hinge and/or hinge pin wear
- Clean and inspect cowling for cracks and/or distortion
- Inspect lower cowling for damaged nutplates
- Inspect access doors and latches for operation and condition, lubricate
- NOTES:________________________________________________________________
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Engine - Lubrication Group:
- Warm engine per oil sample instructions
- Drain oil sump and collect oil sample for analysis
- Remove, clean and inspect oil pump suction and pressure screens
- Remove, then replace spin-on oil filter and safety wire
- Inspect oil cooler fittings and lines for leaks and/or chafing
- Inspect oil cooler condition and door operation
- Inspect oil temperature sender for leaks and security
- Inspect oil pressure sender for leaks and security
- Inspect crankcase breather hose for security and obstructions
- Fill engine with new oil per lubrication chart
- NOTES:________________________________________________________________
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Engine Alternator Group:
- Inspect starter pinion, ring gear for wear and condition, lubricate w/grease
- Inspect propeller weights on ring gear for security
- Inspect starter mountings and lead connection
- Inspect alternator mountings and lead connections
- Inspect alternator condition
- Inspect alternator belt condition and tension
- NOTES:________________________________________________________________
_______________________________________________________________________
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Engine Baffle Group:
- Clean/degrease engine, baffle and airseal gasket surfaces
- Inspect baffle fit and attachment fittings
- Inspect cooling tubes for security and seal
- Inspect baffles and airseal gaskets for condition
- NOTES:________________________________________________________________
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Engine Firewall Group:
- Inspect engine mount for cracks
- Inspect engine mount attachment nuts for security
- Inspect shock isolators, mounting bolts and washers for condition
- Inspect engine mounting bolts for security and torque
- Inspect brake fluid reservoir level, add fluid as required
- Inspect firewall for distortion and cracks
- Inspect firewall to engine ground wire for security and chafing
- Inspect all firewall penetration seals
- Inspect wire bundles for security and chafing
- Inspect vacuum pump and lines for security and condition
- Inspect accessories on rear case for security and leaks
- Inspect crankcase/sump for cracks, leaks and/or missing fasteners
- Inspect barrel base nuts for security
- Inspect rocker box cover gaskets for leaks
- Inspect shroud tubes for leaks
- Inspect inlet tubes for security and leaks
- Inspect exhaust system and mounting brackets for cracks
- Inspect exhaust gaskets for leaks and re-torque mounting nuts
- Inspect heat muffs, heat boxes and SCAT hoses for security
- Inspect cylinder head for bent fins and/or burned paint
- Measure warm WOT compression (PSIg)
1________ 2________ 3________ 4________
- NOTES:________________________________________________________________
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Engine Ignition Group:
- Remove plugs noting current installed location
- Inspect spark plug condition, clean and re-gap
- Rotate plug position/polarity, apply anti-seize and reinstall
- Inspect ignition harness, springs and insulators for condition
- Inspect magneto seals for oil leaks
- Inspect magneto mounting clamps/nuts for security
- Check LASAR magneto timing per LASAR instructions
- NOTES:________________________________________________________________
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Engine Fuel Group:
- Remove and clean gascolator screen and bowl
- Clean carburetor inlet strainer
- Inspect carburetor mounting nuts for security
- Inspect flexible fuel lines for condition and chafing
- Pressurize and inspect fuel system for leaks
- Inspect primer system for leaks
- NOTES:________________________________________________________________
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Engine Intake Group:
- Remove air inlet box and carburetor heat attachments
- Remove, clean and lubricate air filter
- Inspect throttle control cable attachment for condition and security
- Inspect throttle return spring for operation/condition
- Inspect mixture control cable attachment for condition and security
- Inspect mixture return sprint for operation/condition
- Inspect all engine controls for proper movement
- Re-install air inlet box and carburetor heat attachments
- Inspect carburetor heat door, SCAT tubing, and heat muff for operation and condition
- Inspect condition of ram air seal
- Inspect carburetor heat cable attachment for nicks and wear
- NOTES:________________________________________________________________
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Cabin Mechanical Group:
- Remove seats, seat backs, and interior panels
- Inspect wing attach bolts and nuts for proper torque
- Inspect condition of seat belts and shoulder harnesses
- Inspect fire extinguisher condition
- Inspect fuel selector valve operation, lubricate as necessary
- Inspect fuel lines in cabin for leaks and security
- Remove filter screen from FACET pump, clean, and re-install
- Pressurize and inspect fuel system for leaks
- Inspect ELT mount for security
- Inspect static air lines inside empennage for security and chafing
- Inspect fresh air vent lines for security
- Replace vacuum regulator foam filter
- Inspect vacuum lines, replace pleated filter if appropriate
- Inspect transponder, comm, and GPS antenna mounts and wiring for security
- Inspect empennage bulkheads and stringers for cracks and loose rivets
- Inspect GPS ball mount for security and condition
- NOTES:________________________________________________________________
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Cabin Controls Group:
- Inspect elevator and aileron trim servo operation and display
- Inspect flap operation for binding
- Lubricate flap motor arm and all flap connecting rod ends
- Inspect rudder pedal operation and adjustment
- Inspect rudder pedals, cables and attachments
- Inspect brake masters and associated tubing for leaks
- Inspect control sticks, linkages and push/pull tubes
- Lubricate rod ends for both elevator and aileron control tubes
- NOTES:________________________________________________________________
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Cabin Electrical Group:
- Inspect master/starter contactors and associated wiring
- Inspect instruments, lines and attachments
- Inspect instrument lights and rheostat for operation
- Inspect antenna connections and mounting
- Inspect behind firewall for loose wires and chafing lines
- Inspect wire bundles in empennage for security and chafing
- Inspect wire bundles under cockpit floor for security and chafing
- Inspect wire bundles underneath panel for security and chafing
- Inspect ELT batteries free from corrosion and in-service currency
- Verify ELT is armed
- Inspect battery is free from corrosion
- Inspect battery case is free from corrosion
- Inspect fuse panel for condition and wiring chafing
- Check altitude reporting encoder and certification
- Inspect spare fuses available in passenger seat back
- Re-install interior floor panels, seats, flap covers, and seat cushions
- NOTES:________________________________________________________________
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Fuselage Group
- Remove wing root fairings
- Inspect canopy structure and mounting points for security and wear
- Inspect canopy track for operation, lubricate rollers as necessary
- Inspect canopy latching mechanism for cracks and proper operation
- Inspect canopy and windshield for cracks
- Inspect static ports are clear
- Inspect skin for loose rivets, corrosion, and other damage
- Inspect fuel vent ports for security and condition
- Inspect drain holes are open
- NOTES:________________________________________________________________
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Empennage Group
- Remove empennage fairing and fuselage inspection plates
- Inspect rudder and vertical stabilizer for corrosion and condition
- Inspect rudder pivot bolts for proper torque and lubricate
- Inspect rudder control stops for condition
- Inspect rudder cable attachments for security and cotter pin
- Inspect horizontal stabilizer and elevators for corrosion and condition
- Inspect elevator pivot bolts for proper torque and lubricate
- Inspect elevator counterbalance weights for security
- Inspect elevator control stops for condition
- Inspect elevator trim tab, arm, and actuator rod for cracks
- Inspect elevator bellcrank, horns and attachments for corrosion, security, and lubricate
- Inspect vertical stabilizer spar attach points for proper torque
- Inspect horizontal stabilizer spar attach points for proper torque
- Inspect electrical connections for security
- Reinstall inspection plates and fairings
- Inspect drain holes are open
- NOTES:________________________________________________________________
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Tail Wheel Group
- Inspect tail wheel arm attach bolts for security and proper torque
- Inspect tail wheel steering springs for security and proper movement
- Remove tail wheel fairing and wheel assembly
- Grease tail wheel bearings
- Inspect tail wheel for uneven or excess wear
- Clean wheel and fairing of dirt
- Re-assemble and re-install tail wheel assembly
- NOTES:________________________________________________________________
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Wing Group
- Remove inspection plates, landing light lenses, and strobe assemblies
- Inspect structure for corrosion and condition
- Inspect fuel tanks, lines and drains for leaks
- Inspect fuel vents not blocked
- Inspect fuel cap and O ring condition
- Inspect wing root attachment bolt for proper torque
- Inspect wing tank attachment bolt for proper torque
- Inspect fuel sender wiring for security and chafing
- Inspect strobe wiring for security and chafing
- Inspect wing tank attach screws for security
- Inspect aileron attach bolts for proper torque
- Inspect aileron control stops for security
- Inspect aileron trim tab and actuator rod for cracks and security
- Inspect aileron bellcrank for security
- Inspect aileron push tubes for condition and security of jam nuts
- Inspect ailerons for joint alignment in neutral position, adjust if necessary
- Lubricate all aileron rod ends
- Inspect flap system and attachments for slop
- Inspect flap torque tube and mounting plate for cracks/distortion
- Inspect flap actuator rod end and jam nut for security and lubricate
- inspect pitot tube and plumbing for security and blockage
- Inspect landing light fixtures for security
- Inspect strobe light wiring for security and chafing
- Inspect strobe unit attachment points for cracking and corrosion
- Inspect landing light for proper operation
- Clean and re-install landing light lens
- Inspect strobe and position lights for proper operation
- Clean and re-install strobe light assembly
- Reinstall inspection plates and fairings
- NOTES:________________________________________________________________
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Landing Gear Group
- Remove wheel pants and gear leg covers
- Remove tires and brake assemblies
- Inspect tires for wear and cracks, rotate if possible, replace if necessary
- Replace tire tubes if appropriate (every 3 years)
- Inspect brake linings for wear and condition, re-line if necessary
- Pack wheel bearings with grease
- Fill tires with recommended air pressure
- Check brake cylinders for condition and leaks
- Check brake lines for security and chafing
- Thoroughly clean axle/brake area of dust
- Re-mount wheels, tires, and brake assemblies
- Inspect wheel pant attach points for cracks and security
- Inspect gear leg covers for cracks and condition, re-install and secure
- Inspect wheel pants for cracks and condition
- Thoroughly clean wheel pants and re-install
- Inspect gear attach bolts for proper torque
- NOTES:________________________________________________________________
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Operational Inspection
- Visual inspection of engine/propeller
- All inspection panels and fairings secure
- Brake system check
- Check Boost Pump for Proper Pressure
- Engine start procedures
- Oil pressure/oil temperature within limits
- Vacuum check gauge
- Magneto check
- Ignition switch/both magnetos grounded check
- Check alternator shut off/alternate buss operation
- Check fuel gauges for operation
- Check for proper idle RPM
- Check static run up
- Check RPM rise upon leaning mixture
- Check fuel selector for engine shutoff
- Cool down period after shutdown
- Inspect fuel, oil, and hydraulic systems for leaks
- Re-install cowlings, pins and new screws
- NOTES:________________________________________________________________
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Documentation Group
- Verify Registration and Airworthiness Certificate in aircraft
- Verify Operating Limitations and State tax form in aircraft
- Verify pre-flight checklist and Pilots Operating Handbook in aircraft
- Verify external data plate secure and installed
- Verify EXPERIMENTAL placard installed in cockpit
- Verify PASSENGER WARNING placard installed in cockpit
- Review equipment list and update as necessary
- Review Airworthiness Directives for applicability
- Review Service Bulletin/Letter compliance
- Document condition inspection and record maintenance performed
- NOTES:________________________________________________________________
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